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**harrysin** · 03-23-2007, 08:03 AM

Here is a photographic explanation of how the lid was made.

1-Removing waste
2-Stock centred into jig
3-Female template in position
4-Initial clean-up using 1/2" cutter
5-After three cuts
6-After final clean-up with 3/4" dish cutter,packing piece on left,plug (male template) on the right
7-Half inch cutter about to rout the outside
8-As above but showing the ski's
9-Outside finished leaving the last 1/8" for the band saw
10-On the band saw
11-Close-up,who can tell me why the routed groove is stepped?
12-After the band saw
13-Ready to trim
14-Lid looks too deep so will plane some off the inside edge in the ski mode
will also plane off the box round-over
15-Close-up of depth adjustment showing how deep each cut is
16-Planed lid upside-down back in jig ready to rout cut-out for inlay
17-Routing cut-out
18-The cut-out
19-Inlay glued into cut-out
20-Finished box complete with family jewels

I'm sorry, but the pix have become totally jumbled, I shall have a word with Mike to see if they can be sorted. Harry

**bobj3** · 03-23-2007, 08:27 AM

Nice Show And Tell Harry

Good Job

The only thing I don't see is how you hold the template in place to do the outside of the lid I'm guessing it's push in plug in the hole you hogged out in the center of the lid/box.
A 2 step plug type template maybe, GREAT job.

By the way I like the graph paper looking table cloth

now if I knew what size that sq. is, it would tell me the size of the box.

Bj

**harrysin** · 03-23-2007, 08:51 AM

Yes Bob,as mentioned,I planed the lid with the router on the ski's,also you may remember that I put a round-over on the box to cover some tear-out, I also planed this off so that the lid is a nice close fit.The plug,or male template is a tight fit into the box but also has the packing piece below it.Hopefully i shall be able to get the pix into the proper order so that it all makes sense.Cheers, Harry

P.S. Bob,in spite of it being 11.00pm here,just for you I have gone into my shed to measure the squares on the ex-tablecloth,now a dust sheet,they are exactly 1" squares.Harry

2nd edit. My wife has just told me that it was a bed sheet, not a tablecloth!

**bobj3** · 03-23-2007, 09:03 AM

Thanks Harry ,1" will help

me and others I'm sure
"bed sheet" =LOL, that's makes it easy ,this is your side and from this mark it's mind

, Good Night Harry

Here's a tip I use.

"proper order"=

box-lid-lid-1
box-lid-lid-1A
box-lid-lid-1B
box-lid-lid-1C
box-lid-lid-1D
and so on

Bj

**Bob** · 03-23-2007, 10:10 AM

Great photo turtorial Harry! Sure gives me some ideas to consider.

Joe Lyddon · 03-23-2007, 10:31 AM

Very nice Harry.

I like that inlay... did you make it? Did you use an inlay router guide inlay kit to do it?

Looks like it went very much like the box but not so deep... and you went skiing this time.

Nice job!

curiousgeorge · 03-23-2007, 02:05 PM

Excellent job Harry. The box came out great. Thank you for the pictorial.

template tom · 03-23-2007, 05:13 PM

Thanks Harry
That was a great pictorial explanation. Now I hope others will see there is no need for the bandsaw to shape the outside then use sanding machine to produce the finish. Routing the edge will produce a better surface and also consistant thickness to the sides. (Subject to producing a neat 'Male' template) The male template (PLUG) can be produced with the router once you work out the off-set and it will fit neatly into the base of the box. Excellent job with the inlay on the top of the box.
Tom

Joe Lyddon · 03-23-2007, 08:39 PM

Quote:

Originally Posted by template tom

Thanks Harry
That was a great pictorial explanation. Now I hope others will see there is no need for the bandsaw to shape the outside then use sanding machine to produce the finish. Routing the edge will produce a better surface and also consistant thickness to the sides. (Subject to producing a neat 'Male' template) The male template (PLUG) can be produced with the router once you work out the off-set and it will fit neatly into the base of the box. Excellent job with the inlay on the top of the box.
Tom

I will just say that I still feel it's better & safer to cut the outside with a bandsaw followed by trimming with a router (to get the same result) or sanding. To each his own...

Nice job Harry!! Looks great!

Still curious about the nice inlay...

**harrysin** · 03-23-2007, 09:47 PM

Hi Joe,the inlay is purchased as shown in pix 13th from top left,it also shows the template that I made with a hole in the centre for the template guide.The router could easily have been used hand held as it sits on top of the template but as I have mentioned in the past,using the router on ski's gives better control and it gives a feeling that from memory is almost as good as sex! I shall attach a pix of some inlays that I use and are readily available over here also a couple more shots of the box after staining but prior to polishing with Danish oil.Keep watching,Harry

03-23-2007, 08:03 AM	#1
harrysin Forum Contributer Supreme Forum King Join Date: Jan 2007 Location: Western Australia Posts: 2,651 View harrysin's Gallery	Completion of routed box-the lid Here is a photographic explanation of how the lid was made. 1-Removing waste 2-Stock centred into jig 3-Female template in position 4-Initial clean-up using 1/2" cutter 5-After three cuts 6-After final clean-up with 3/4" dish cutter,packing piece on left,plug (male template) on the right 7-Half inch cutter about to rout the outside 8-As above but showing the ski's 9-Outside finished leaving the last 1/8" for the band saw 10-On the band saw 11-Close-up,who can tell me why the routed groove is stepped? 12-After the band saw 13-Ready to trim 14-Lid looks too deep so will plane some off the inside edge in the ski mode will also plane off the box round-over 15-Close-up of depth adjustment showing how deep each cut is 16-Planed lid upside-down back in jig ready to rout cut-out for inlay 17-Routing cut-out 18-The cut-out 19-Inlay glued into cut-out 20-Finished box complete with family jewels I'm sorry, but the pix have become totally jumbled, I shall have a word with Mike to see if they can be sorted. Harry Attached Thumbnails Last edited by harrysin; 03-23-2007 at 08:22 AM.
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03-23-2007, 08:27 AM	#2
bobj3 Forum Contributer Supreme Forum King Join Date: Jan 2006 Location: Littleton,Colorado U.S.A. Posts: 7,080 View bobj3's Gallery	Nice Show And Tell Harry Good Job The only thing I don't see is how you hold the template in place to do the outside of the lid I'm guessing it's push in plug in the hole you hogged out in the center of the lid/box. A 2 step plug type template maybe, GREAT job. By the way I like the graph paper looking table cloth now if I knew what size that sq. is, it would tell me the size of the box. Bj __________________ *Router Tables plans FREE, plus more* http://www.absolutelyfreeplans.com/W...p_projects.htm Router Tip Archive http://www.routerworkshop.com/router_tip_glossary.html Calculators http://www.routerforums.com/dynamic-calculators/ Last edited by bobj3; 03-23-2007 at 11:37 AM.
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03-23-2007, 08:51 AM	#3
harrysin Forum Contributer Supreme Forum King Join Date: Jan 2007 Location: Western Australia Posts: 2,651 View harrysin's Gallery	The box Yes Bob,as mentioned,I planed the lid with the router on the ski's,also you may remember that I put a round-over on the box to cover some tear-out, I also planed this off so that the lid is a nice close fit.The plug,or male template is a tight fit into the box but also has the packing piece below it.Hopefully i shall be able to get the pix into the proper order so that it all makes sense.Cheers, Harry P.S. Bob,in spite of it being 11.00pm here,just for you I have gone into my shed to measure the squares on the ex-tablecloth,now a dust sheet,they are exactly 1" squares.Harry 2nd edit. My wife has just told me that it was a bed sheet, not a tablecloth! Last edited by harrysin; 03-23-2007 at 09:05 AM.
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03-23-2007, 09:03 AM	#4
bobj3 Forum Contributer Supreme Forum King Join Date: Jan 2006 Location: Littleton,Colorado U.S.A. Posts: 7,080 View bobj3's Gallery	Thanks Harry ,1" will help me and others I'm sure "bed sheet" =LOL, that's makes it easy ,this is your side and from this mark it's mind , Good Night Harry Here's a tip I use. "proper order"= box-lid-lid-1 box-lid-lid-1A box-lid-lid-1B box-lid-lid-1C box-lid-lid-1D and so on Bj __________________ *Router Tables plans FREE, plus more* http://www.absolutelyfreeplans.com/W...p_projects.htm Router Tip Archive http://www.routerworkshop.com/router_tip_glossary.html Calculators http://www.routerforums.com/dynamic-calculators/ Last edited by bobj3; 03-23-2007 at 09:09 AM.
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03-23-2007, 10:10 AM	#5
Bob Forum Moderator Supreme Forum King Join Date: Oct 2004 Location: Metro Atlanta, GA Posts: 2,228 View Bob's Gallery	Great photo turtorial Harry! Sure gives me some ideas to consider. __________________ Cheers, Bob Pictures from the shop http://s107.photobucket.com/albums/m292/bnoles616/
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03-23-2007, 10:31 AM	#6
Joe Lyddon Banned Supreme Forum King Join Date: Sep 2004 Location: Alta Loma, CA USA Posts: 2,168 View Joe Lyddon's Gallery	Very nice Harry. I like that inlay... did you make it? Did you use an inlay router guide inlay kit to do it? Looks like it went very much like the box but not so deep... and you went skiing this time. Nice job!
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03-23-2007, 02:05 PM	#7
curiousgeorge Registered User Supreme Forum King Join Date: Nov 2006 Location: Fort Worth,Texas USA Posts: 1,329 View curiousgeorge's Gallery	Excellent job Harry. The box came out great. Thank you for the pictorial. __________________ George If you can't fix it with a hammer, you've got an electrical problem...
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03-23-2007, 05:13 PM	#8
template tom Registered User Forum King Join Date: Sep 2004 Posts: 515 View template tom's Gallery	Thanks Harry That was a great pictorial explanation. Now I hope others will see there is no need for the bandsaw to shape the outside then use sanding machine to produce the finish. Routing the edge will produce a better surface and also consistant thickness to the sides. (Subject to producing a neat 'Male' template) The male template (PLUG) can be produced with the router once you work out the off-set and it will fit neatly into the base of the box. Excellent job with the inlay on the top of the box. Tom Last edited by template tom; 03-23-2007 at 05:15 PM. Reason: spellcheck
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03-23-2007, 09:47 PM	#10
harrysin Forum Contributer Supreme Forum King Join Date: Jan 2007 Location: Western Australia Posts: 2,651 View harrysin's Gallery	The box Hi Joe,the inlay is purchased as shown in pix 13th from top left,it also shows the template that I made with a hole in the centre for the template guide.The router could easily have been used hand held as it sits on top of the template but as I have mentioned in the past,using the router on ski's gives better control and it gives a feeling that from memory is almost as good as sex! I shall attach a pix of some inlays that I use and are readily available over here also a couple more shots of the box after staining but prior to polishing with Danish oil.Keep watching,Harry Attached Thumbnails
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